Integral cover-deployment chute for side airbag module

ABSTRACT

A flexible sheet of material forms an integral airbag module housing enclosing an inflator and inflatable airbag, which cover also acts as a deployment chute guiding the deployment of the inflating airbag to the desired deployment location in a motor vehicle.

FIELD OF THE INVENTION

This invention relates to an integral cover-deployment chute for a sideairbag module for attachment to an internal structural member of a seat.

BACKGROUND OF THE INVENTION

Side impact airbag modules have been provided in vehicles for protectingvehicle occupants in the event of a side oriented collision. Such sideimpact airbag modules have been installed in a variety of locations inthe vehicle, including, for example, in the door, roof, A or B--pillarsand also in the seats of the vehicle. When placed in seats of vehicles,such side airbag modules are generally anchored or secured to aninternal structural member of the seat. Such seat mounted side airbagmodules generally include a rigid plastic or an extruded or drawn orcast metal container-type housing which houses an inflator and aninflatable folded airbag cushion.

Typically, such rigid housing will have some type of deployment doorwhich bursts open to permit deployment of the airbag out from the seat.While the airbag module is generally placed in a recess in the seatback, usually in a recess in the foam cushion portion of the seat back,the module cannot be located too close to the outer trim cover of theseat due to the hardness and rigidity of both the housing and itsassociated door since these can undesirably alter the smooth contour ofthe outer trim cover of the seat and also can produce hard or stiffareas that can cause discomfort to the seat occupant. However, when theairbag module is located in the recess in a location remote from theouter trim cover of the seat, deployment of the airbag through thedesired deployment opening in the seat becomes problematic andunpredictable.

It is therefore an object of this invention to provide an integralhousing or cover for a side airbag module that also acts as a deploymentchute to consistently guide and direct the inflating airbag to thedesired deployment location in the seat outer trim cover along apredetermined deployment path. A further object of this invention is toprovide such a housing or cover for a seat mounted airbag module that isa unitary, single component cover that is easy to produce and islightweight and is soft and flexible so as not to produce stiff pointsin the outer trim cover of the seat.

SUMMARY OF THE INVENTION

This invention provides an airbag module including an inflator forgenerating inflation gas and a folded, inflatable airbag connected tothe inflator for receiving inflating gas from the inflator whendeployment of the airbag is desired. The airbag module further includesa module cover that serves as both a cover or housing of the airbagmodule and as a deployment chute or director for the inflating airbag.

The module cover can be made of either fabric or a thin flexible plasticsheet. The module cover has wall portions surrounding or encircling thefolded airbag and the inflator. These wall portions define a coverinterior containing the inflator and the folded airbag. Ends of saidwall portions are brought together to define an unsealed seam which isopenable to form a deployment chute opening for guiding and directingthe inflating airbag out of the cover housing to the desired deploymentexit or opening in the seat outer trim cover.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is illustrated by way of the following exemplaryembodiment in reference to the following drawings in which:

FIG. 1 is a perspective view of a sheet of material employed to form ahousing cover for an airbag module of the invention;

FIG. 2 is a sectional view of an embodiment of the airbag module with ahousing of this invention located in the seat of a vehicle, the airbagbeing in an undeployed state; and

FIG. 3 is a view similar to FIG. 2 but showing the airbag of the airbagmodule in its deployed state.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, there is shown a sheet of material, for forming amodule housing cover 10 of this invention, prior to employing it toenclose an airbag module. The housing cover 10 is a flexible sheet 12 ofmaterial, which may be either fabric or a flexible plastic material,such as a thin, extruded sheet of thermoplastic polyolefin. The sheet ofmaterial 12 comprising the cover 10 is provided with mounting apertures14, 16, for a purpose discussed hereinafter, intermediate opposite edges17, 18 of the sheet. The sheet material 12 comprises wall portions 58between the apertures 14, 16 and the opposing edges 17, 18.

Although the cover 10 is suitable for housing an airbag module invarious locations in a motor vehicle, it is illustrated in FIGS. 2 and 3as a housing for a side airbag module 30.

The upper seat back portion 20 of the seat 19 includes an internalstructural member, such as a rigid seat frame rail 21, preferably beingmetal, and encompassed within a cushion portion 22 of the seat back 20.The cushion portion 22 is preferably formed of a foam material 23covered by fabric seat material 24 defining the contour of the outersurface 25 of the seat back 20. A front 26 of the outer surface 25 ofthe seat back 20 includes a vertically extending frangible seat seam 27proximate the inner door panel of a vehicle door (not shown). A recess28 is provided in the foam material 23 for receiving an airbag module,generally designated by the reference numeral 30. A deployment line 29is provided in the foam cushion 23 from or proximate the recess to orproximate the frangible seat seam 27. The deployment line 29 could, forexample, be a line of perforations or a tear seam or even a narrow slitor channel in the foam cushion 23.

A complete airbag module 30 includes an inflator 40, an airbag 50 havinga partially folded deployment portion 51 and a mouth portion 52, andmounting studs 45 (only one being shown) extending from the inflator 40for mounting the entire module 30 to any suitable vehicle structure.

The inflator 40 may be of any conventional construction which containschemicals for igniting to generate gas for discharge upon the existenceof predetermined vehicle conditions. The inflator 40 is rigid andpreferably has an axially elongated cylindrical body 41 including ports(not shown) through which the inflator gas discharges to inflate theairbag 50.

The elongated mounting studs 45 are secured to the body 41 of theinflator 40 and extend radially outwardly therefrom for attachment toany suitable vehicle structure, such as the seat frame rail 21. Themounting studs 45 preferably each have a threaded end 46 for receiving anut 48 thereon, as shown.

The airbag 50 includes the partially folded deployment portion 51 whichis inflatable upon the discharge of inflator gas. The deployment portion51 includes folds 53 which are oriented forwardly on the module 30 fordeployment in a forwardly direction. The mouth portion 52 of the airbag50 has apertures 54, 55 for attaching the mouth around the inflator body41 by placing the apertures over the studs 45 before the studs aremounted to the internal structural member 21.

The airbag module 30 also includes the housing cover 10 enclosing theairbag 50 and inflator 40. Mounting apertures 14, 16 of the housingcover 10 are placed over and around elongated mounting studs 45 whichare attached to the seat structural member 21. The wall portions 58 ofthe sheet 12 cooperatively defines an insertion opening through whichthe airbag 50 and inflator 40 are insertable into the housing 10. Thetwo side wall portions 58 are wrapped around the airbag 50 and inflator40 with areas of the side walls adjacent the sheet edges 17, 18 beingbrought together to define an unsealed seam 62. In the illustratedembodiment the housing 10 is shaped to form a tear drop or clam shellshaped housing. It will be appreciated that the flexible sheet 12 of thehousing could be formed into any suitable shape depending upon the shapeof the inflator 40 and the folded deployment portion 51 of the airbag50. It will also be understood that the shape of the recess 28 in theseat cushion 22 will be shaped to be complementary to the shape of thehousing 10.

The side wall portions 58 thus define an enclosed housing interior 59including an unsealed seam 62 which closes a housing deployment opening60.

The side wall portions 58 form the enclosed housing interior 59 whichcompletely encloses, houses, and covers the inflator 40 and the mouth 52and deployment portions 51 of the airbag 50. The side wall portions 58are sized for closely surrounding the inflator 40 and the mouth anddeployment portions 52, 51 of the airbag 50. The unsealed seam 62 isadjacent and overlying the folds 53 of the deployment portion 51 of theairbag 50 such that the unsealed seam 62 opens on deployment of theairbag 50 to define the housing deployment opening 60 through which thedeployment portion 51 of the airbag 50 deploys, as shown in FIG. 3.

Referring to FIG. 3, the housing portion 10 also includes an integralchute portion 66 extending forwardly beyond the area of the unsealedseam 62 and having an open free end 68 opposite the unsealed seam 62.The free end 68 of the chute portion 66 defines a chute opening 69 asbest shown in FIG. 3. The chute portion 66 guides the deployment portion51 of the airbag 50 during deployment, as described below.

The entire module 30 is located completely within the cushion portion 22of the seat back 20 and is mounted to the seat frame rail 21. Prior todeployment, the unsealed seam 62 of the deployment portion 51 ispreferably aligned with the frangible seat seam 27 of the seat back 20.The unsealed seam 62 and the chute portion 66 of the housing 10 arelocated proximate the outer surface 25 of the seat back 20 by beingplaced proximate or in the deployment line 29 in foam cushion 23, whilethe rigid inflator 40 is oriented away from the outer surface 25 of theseat 19. Thus, the module 30 only has soft fabric components facing theouter surface 25 of the seat 19 such that any stiff points caused by therigid components such as the housing and cover normally found in priorart modules are eliminated. Advantageously, this enables the module 30to be located closely beneath the outer surface 25 of the seat 19 whilemaintaining the comfort of the seat 19 for the occupant.

Assembly of the airbag module 30 and its mounting into the seat 19 isaccomplished as follows. The apertures 54, 55 of the mouth portion 52 ofthe airbag 50 are placed over mounting studs 45 of the inflator 40 andthe deployment portion 53 of the airbag is suitably folded. Theapertures 14, 15 of the housing sheet 12 are also placed on the studs 45over the airbag mouth portion 52. The wall portions 58 of the housingsheet 12 are then flexed and brought together at their edges 17, 18enclosing the airbag 50 and inflator 40. Proximate the edges 17, 18 thewall portion 58 are brought together providing the unsealed seam 62 toform the enclosed housing 59. The airbag module 30 can now be mounted inthe seat 19 by inserting the module in recess 28 and the unsealed seam62 and chute portion 66 of the housing in or proximate deployment line29 of foam cushion 23, placing mounting studs 45 through the internalmounting member 21 and threading nuts 48 onto the threaded ends 46 ofthe studs. The front portion 26 of outer trim cover 25 of seat 19 canthen be sewn to provide the frangible seat seam 27 and close up the seattrim cover.

Referring to FIG. 3, when inflator 40 is actuated upon a signal from asensor (not shown), the inflator provides inflation gas to the airbag 50to begin inflation of the deployment portion 51 of the airbag. Thedeployment portion 51 of the airbag inflates and folds 53 expand andopen unsealed seam 62 of the housing 10 so that the airbag 50 deploysout through the deployment opening 60 of the housing 10 into the chuteportion 66 and then out through chute opening 69 and along deploymentline 29 to a location immediate adjacent frangible seam 27 of seat 19.The deploying airbag 50 causes the foam material to deform and therebyrupture frangible seam 27 permitting the airbag to deploy into thedesired area of the vehicle for protection of a vehicle occupant.

It will be understood that the chute portion 66 of the housing 10 guidesthe deployment direction and location of the inflating airbag 50.

It will be understood that: the foregoing description of embodiments ofthis invention are only for illustration of the invention and that thoseskilled in the art can make various modifications thereto withoutdeparting from the spirit and scope of the invention.

I claim:
 1. An airbag module for attachment to a vehicle, the modulecomprising:an inflator for generating gas; an airbag coupled to theinflator and deployable upon generation of gas by the inflator; ahousing made of a unitary sheet of flexible material, the housing havingwall portions surrounding the airbag and inflator, the wall portionsdefining a housing interior containing the inflator and the airbagsubstantially therein such that the inflator and the airbag are enclosedwithin the housing, the wall portions of the housing defining anunsealed seam being openable to define a housing deployment opening; andthe housing including a chute portion being a continuous extension ofthe flexible material of the housing and extending beyond the unsealedseam, the chute portion having a first end adjacent the unsealed seamand an opposite free end;whereby upon airbag deployment, the airbagopens the unsealed seam of the housing to permit deployment of theairbag out through the housing deployment opening and the chute portionof the housing such that the housing guides the airbag duringdeployment.
 2. An airbag module of claim 1 wherein the flexible materialof the housing is a flexible sheet of plastic material.
 3. An airbagmodule of claim 2 wherein the housing is a tear drop shaped housing. 4.An airbag module for attachment to a vehicle, the module comprising:aninflator for generating gas; an airbag coupled to the inflator anddeployable upon generation of gas by the inflator; and a housing forhousing the airbag and inflator, the housing being the outermost portionof the airbag module, the housing made of flexible material, the housinghaving wall portions surrounding the airbag and inflator, the wallportions defining a housing interior containing the inflator and theairbag substantially therein, the wall portions of the housing togetherdefining an unsealed seam being openable to define a housing deploymentopening;whereby upon airbag deployment, the airbag breaks open theunsealed seam of the housing to permit deployment of the airbag outthrough the housing deployment opening such that the housing guides theairbag during deployment.
 5. An airbag module of claim 4 wherein theflexible material of the housing is a flexible sheet of plasticmaterial.
 6. An airbag module of claim 5 wherein the housing is a teardrop shaped housing.
 7. A vehicle seat comprising:a seat back having anouter trim cover defining a frangible seam therein for deployment of aninflating airbag, said outer trim cover enclosing a foam cushiondefining a recess for receiving an airbag module, a deployment linedefined in said foam cushion from proximate said recess to proximatesaid frangible seam in the outer trim cover, and an internal structuralmember to which is mounted an airbag module received in said recess, theairbag module comprising:an inflator for generating gas; an airbagcoupled to the inflator and deployable upon generation of gas by theinflator; a housing made of a unitary sheet of flexible material, thehousing having wall portions surrounding the airbag and inflator, thewall portions defining a housing interior containing the inflator andthe airbag substantially therein such that the inflator and the airbagare enclosed within the housing, the wall portions of the housingdefining an unsealed seam being openable to define a housing deploymentopening; and the housing including a chute portion being a continuousextension of the flexible material of the housing and extending beyondthe unsealed seam, the chute portion having a first end adjacent theunsealed seam and an opposite free end; said unsealed seam and chuteportion being located proximate or in said deployment line of the foamcushion;whereby upon airbag deployment, the airbag opens the unsealedseam of the housing to permit deployment of the airbag out through thehousing deployment opening and the chute portion of the housing suchthat the housing guides the airbag along the deployment line to thefrangible seam of the seat during deployment.
 8. The vehicle seat ofclaim 7 wherein the deployment line is a narrow slit in the foamcushion.
 9. A vehicle seat of claim 8 wherein the flexible material ofthe housing is a flexible sheet of plastic material.
 10. A vehicle seatof claim 9 wherein the housing is a tear drop shaped housing.
 11. Avehicle seat comprising:a seat back having an outer trim cover defininga frangible seam therein for deployment of an inflating airbag, saidouter trim cover enclosing a foam cushion defining a recess forreceiving an airbag module, a deployment line defined in said foamcushion from proximate said recess to proximate said frangible seam inthe outer trim cover, and an internal structural member to which ismounted an airbag module received in said recess, the airbag modulecomprising:an inflator for generating gas; an airbag coupled to theinflator and deployable upon generation of gas by the inflator; ahousing made of a unitary sheet of flexible material, the housing havingwall portions surrounding the airbag and inflator, the wall portionsdefining a housing interior containing the inflator and the air bagsubstantially therein such that the inflator and the airbag are enclosedwithin the housing, the wall portions of the housing defining anunsealed seam being openable to define a housing deployment opening; andthe housing including a chute portion being a continuous extension ofthe flexible material of the housing and extending beyond the unsealedseam, the chute portion having a first end adjacent the unsealed seamand an opposite free end; said unsealed seam and chute portion beinglocated proximate or in said deployment line of the foam cushion;wherebyupon airbag deployment, the airbag opens the unsealed seam of thehousing to permit deployment of the airbag out through the housingdeployment opening such that the housing guides the airbag along thedeployment line to the frangible seam of the seat during deployment. 12.The vehicle seat of claim 11 wherein the deployment line is a narrowslit in the foam cushion.
 13. A vehicle seat of claim 12 wherein theflexible material of the housing is a flexible sheet of plasticmaterial.
 14. A vehicle seat of claim 13 wherein the housing is a teardrop shaped housing.